Load bearing panel assembly

Abstract

A panel assembly includes at least one reinforcing assembly made of a high strength material having a low yield to tensile strength ratio for energy absorption and reduced weight and profile. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The panel assembly may be a floor panel assembly for a vehicle floor. The reinforcing assembly may traverse the panel such that the reinforcing assembly extends laterally, e.g., cross-vehicle, relative to the longitudinal axis of the vehicle body. A method of making the panel assembly may include forming the reinforcing assembly by joining a plurality of metal channel members in a nested arrangement with a plurality of welds to provide a structural assembly with good bending resistance loads imposed on the panel assembly including knee loads. The channel members can be made of dual phase steel.

1 . A bracket comprising:
 opposing first and second flanges; and   a strap disposed between and connecting the first and second flanges;   wherein the strap defines an opening to receive a component such that the strap surrounds the component;   a first tang portion defined by one of the first and second flanges;   wherein the first tang portion extends into the opening such that the component is retained in the opening by the tang portion.   
     
     
         2 . The bracket of  claim 1 , further comprising a second tang portion defined by the other of the first and second flanges;
 wherein the second tang portion extends into the opening and cooperates with the first tang portion to retain the component in the opening.   
     
     
         3 . The bracket of  claim 2 , wherein the bracket is made of a bendable material such that the bracket is bendable to:
 receive a component between the first and second tang portions and into the opening; and   to exert a compressive force on the component received in the opening.   
     
     
         4 . The bracket of  claim 3 , wherein the bracket is made of a polymer-based material. 
     
     
         5 . The bracket of  claim 1 , wherein the first tang portion is tapered. 
     
     
         6 . The bracket of  claim 1 , wherein the strap includes a bridge portion;
 wherein the bridge portion is separated from each of the first and second flanges by the opening.   
     
     
         7 . The bracket of  claim 6 , wherein the first tang portion is parallel to the bridge portion. 
     
     
         8 . A molded assembly including a molded component, the molded assembly comprising:
 a bracket including:
 opposing first and second flanges; and 
 a strap disposed between and connecting the first and second flanges; 
 wherein the strap includes a bridge portion defining an opening between the bridge and each of the first and second flanges; 
 wherein at least one of the first flange, the second flange, and the bridge portion defines at least one aperture; 
   a molded component including at least one projection;   wherein the at least one projection projects into the at least one aperture to attach the bracket to the molded component.   
     
     
         9 . The molded assembly of  claim 8 , wherein the projection is formed by material flowing from the molded component into the aperture during the molding operation such that the projection has a shape defined by the aperture. 
     
     
         10 . The molded assembly of  claim 9 , wherein the bracket is made of a polymer-based material; and
 wherein the molded assembly further includes a polymeric bond formed between the bracket and the molded component.   
     
     
         11 . A method of forming a molded assembly, the method comprising:
 inserting a first non-metallic sheet in a mold;   wherein the mold defines a first component and a second component;   inserting a bracket into the mold;   inserting a second non-metallic sheet into the mold such that the bracket is interposed between the first and second sheets; and   molding the molded assembly such that the molded assembly comprises:   the first component formed from the first sheet;   a second component formed from the second sheet;   wherein:
 the first and second components are operatively attached to each other; 
 the bracket is contained between the first and second components; and 
 at least one of the first and second components projects into the bracket to operatively attach the bracket and said at least one of the first and second components. 
   
     
     
         12 . The method of  claim 11 , wherein the bracket defines an aperture; and molding the molded assembly further comprises:
 said at least one of the first and second components projecting into the aperture to operatively attached the bracket and said at least one of the first and second components.   
     
     
         13 . The method of  claim 11 , wherein the bracket is made of a polymer-based material; and
 molding the molded assembly further comprises:
 forming a polymeric bond between the bracket and at least one of the first and second components. 
   
     
     
         14 . The method of  claim 11 , wherein the bracket defines an opening to receive a third component; and
 molding the molded assembly further comprises:
 inserting the third component into the opening prior to inserting the second non-metallic sheet into the mold, such that the third component is retained in the bracket and interposed between the first and second sheets. 
   
     
     
         15 . The method of  claim 14 , wherein the third component is retained in the bracket such that the third component is slidably attached to the bracket. 
     
     
         16 . The method of  claim 14 , wherein the bracket further comprises:
 opposing first and second flanges; and   a strap disposed between and connecting the first and second flanges;   wherein the strap defines the opening.   
     
     
         17 . The method of  claim 16 , wherein the bracket further comprises:
 a tang portion defined by at least one of the first and second flanges;   wherein the tang portion extends into the opening and is in contact with the third component to retain the component in the opening.   
     
     
         18 . The method of  claim 16 , wherein the strap is configured to exert a compressive force on the third component such that the third component is retained in the bracket by the compressive force. 
     
     
         19 . The method of  claim 11 , further comprising:
 forming a rib in one of the first and second components such that the bracket is at least partially disposed in the rib.